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HYDRAULIC CLAMPING ARRANGEMENT FOR CONNECTING ROD MILLING FIXTURE

SUBMITTED BY:AJINKYA VIJAY MORE(11MCD0013) GUIDED BY:DR.K ANNAMALAI.
School of Mechanical and Building Sciences, VIT University, Vellore - 632014, TamilNadu, India
ABSTRACT Now a days all manufacturing industries are attempts to bring down the manufacturing time and resources. For that purpose they have in search of various types of specific manufacturing systems. Fixtures are one of the mean that it accomplish this need effectively. We design and manufacture the Connecting Rod Milling Fixture With Hydraulic Clamping Arrangement, which can potentially reduce the process time and almost eliminates setup time.
. This need of fixture for following purposes 1. It works as work holding device. 2. It is base to machining theory.
NEED OF PROJECT:For milling of five components i.e. Split Type Connecting Rods. They need for Vertical Machining Centre (V.M.C.) with precise accuracy and reduced time of machining. Present method of machining makes use of stoppers and clamps only which require long processing time. Maximum time of worker is wasted in setting of work piece on the machine. Also accuracy is not so precise. Therefore to get the precise accuracy company needs this fixture. Hydraulic clamping arrangement provides perfect clamping action & reduces time of adjusting connecting rods on fixture. At a time 4 connecting rods can be milled on this fixture. Due to this setting time can be reduced.. It is robust structure.
COMPONENTS USED FOR HYDRAULIC CLAMPING
1) Hydro line 32:-Anti corrosion, anti oxidation, anti wear, anti foam additives specially selected to maintain good air- release properties. Theses oils are recommended for use in general hydraulic systems,
2) Hydraulic cylinder Hydraulic cylinders get their power from pressurized hydraulic fluid, which is typically oil. The hydraulic cylinder consists of a cylinder barrel, in which a piston connected to a piston rod moves back and forth. The barrel is closed on each end by the cylinder bottom (also called the cap end) and by the cylinder head where the piston rod comes out of the cylinder. The piston has sliding rings and seals. The piston divides the inside of the cylinder in two chambers, the bottom chamber (cap end) and the piston rod side chamber (rod end). The hydraulic pressure acts on the piston to do linear work and motion. Flanges, trunnions, and/or clevisses are mounted to the cylinder body. The piston rod also has mounting attachments to connect the cylinder to the object or machine component that it is pushing.
3) Hydraulic accumulator:A hydraulic accumulator is an energy storage device. It is a pressure storage reservoir in which a non-compressible hydraulic fluid is held under pressure by an external source. That external source can be a spring, a raised weight, or a compressed gas. The main reasons that an accumulator is used in a hydraulic system are so that the pump doesn't need to be so large to cope with extremes of demand, so that the supply circuit can respond more quickly to any temporary demand and to smooth pulsations. In modern, often mobile, hydraulic systems the preferred item is a gas charged accumulator, but simple systems may be spring-loaded. There may be more than one accumulator in a system. The exact type and placement of each may be a compromise due to its effects and the costs of manufacture. An accumulator is placed close to the pump with a non-return valve preventing flow back to it. In the case of piston-type pumps this accumulator is placed in the best place to absorb pulsations of energy from the multi-piston pump. It also helps protect the system from fluid hammer. This protects system components, particularly pipework, from both potentially destructive forces. An additional benefit is the additional energy that can be stored while the pump is subject to low demand. The designer can use a smaller-capacity pump. The large excursions of system components, such as landing gear on a large aircraft, that require a considerable volume of fluid can also benefit from one or more accumulators. These are often placed close to the demand to help overcome restrictions and drag from long pipe work. The outflow of energy from a discharging accumulator is much greater, for a short time, than even large pumps could generate. An accumulator can maintain the pressure in a system for periods when there are slight leaks without the pump being cycled on and off constantly. When temperature changes cause pressure excursions the accumulator helps absorb them. Its size helps absorb fluid that might otherwise be locked in a small fixed system with no room for expansion due to valve arrangement. The gas precharge in an accumulator is set so that the separating bladder, diaphragm or piston does not reach or strike either end of the operating cylinder. The design precharge normally ensures that the moving parts do not foul the ends or block fluid passages. Poor maintenance of precharge can destroy an operating accumulator. A properly designed and maintained accumulator should operate trouble-free FOR YEARS
JUSTIFICATION OF FIXTURE: 1. To reduce the cost of production and setting up costs. 2. To increase production. 3. To assure high accuracy of part. 4. To increase versatility of the machine. 5. Saving of labour. 6. To reduce the quality control expenses.
7. To use less skilled labour. 8. To improve safety at the work and thereby reduce rate of accidents
DESIGN PRINCIPLE FOR FIXTURE

Locating:Locating refers establishment of a proper relation between the work piece and the fixture.
Let us consider a work piece in a space. The work piece is assumed to have true and flat faces. In a state of freedom, it moves in either of the two apposed directions along three mutually perpendicular axes, XX, YY, and ZZ. These six movements are called movement of translation. Also the work piece can rotate in either of two opposed
directions around each axis, clockwise and round wise. These movements are called rotational movements. The sum of these two types of movements gives the twelve degree of freedom of work piece in space. To confine the work of piece accurately and positively in another fixed body , the movements of work piece in any of the twelve degree of freedom must be restricted .
PROCESS SHEET
1) PART NAME: - CASTING BASE Raw Material Size: - 500X 340X 195 Material: - C.I.
Sr. No . 1
Operation
Machine
Tool Used
Feed
Speed
Depth of cut
Inspection Instruments
TIME ( MIN)
Milling
HOR Boring Machine CBH 100
T-Max cutter
0.05 mm
650 rpm
2mm
Vernier calliper and steel rule
240
Drilling
Various sizes of drills Dia 67.5,13.5, 6 Reamer dia. 14
3 mm
625 rpm
2mm
Vernier calliper
300
Boring
Size 50 boring tool
0.05 mm
1000 rpm
2mm
Vernier caliper, Micrometer
600
Spot facing
SS Slot drill
0.01 mm
800 rpm
1mm
90
Surface Grinding
ELB Surface Grinding Machine
inch bsp
Micrometer
240
Fitter work including dia. 8 extra long drills, tapping
ELB Surface Grinding Machine
120
Slots of 14 Dekel mm Milling Machine,
End Mill cutter dia.12
0.05 mm
650 rpm
2mm
180
Jig/ Boring mm Machine (Double column) dia 6 X 16, 6H7 dia. 55 finish bore, dia.12H7 (3 holes), dia 18H7 (4 holes)
CMM Inspection
Inspection
3- D Coordinate Inspectio n
240
2) PART NAME: - FIXED BLOCK Raw Material Size: - 50X 60X 115 Material:- EN353
Sr. No. 1
Operation
Machine
Tool Used
Feed
Speed Depth Inspection of cut Instruments Vernier calliper and steel rule
TIME (MIN) 350
Blank and Step Milling
BFW VF2 Milling Machine
Tmax & End Mill cutter
0.05 mm
650 rpm
3mm
Fitter work (Marking, Drilling, Tapping)
No.6 tap, Drill of 7&11
330
Heat Treatment Case Hardening
Dynamic Hardness Tester FANSE PRAGA 451 Surface Grinding Machine Grinding Wheel Micrometer
60
Surface Grinding
240
Slots
Dekel Milling Machine FP4M. 1549
End Mill Cutter
0.05 mm
650 rpm
2mm
180
7H7, 6H7 Dowel
Jig Boring Machine (Double Column)
Jig Boring Tool
0.05 mm
650 rpm
3mm
Vernier calliper and Micrometer
210
Dia. 18 Wire Cut
CNC Spark Errosion EDM Machine
Copper Electrode
Vernier calliper
180
3) PART NAME: - ORIENTATION BLOCK Raw Material Size: - 70 X 35X 20 Material: - EN353
Sr. No. 1
Operation
Machine Tool Used
Feed
Speed Depth Inspection of cut Instruments Vernier
TIME (MIN) 60
Turning
LB17
Turning
0.1m
1000
2mm
Lathe
&
rpm
caliper
Machine Facing Tool 2 Step Milling BFW Tmax & 0.05 mm 600 rpm 3mm Vernier calliper 180
HF2 091 End Milling Fitter Marking & Drilling 4 Heat Treatment Case Hardening 5 Surface Grinding CNC Arc Milling Machine Mill
Machine Cutter 3 Vernier calliper and steel rule Dynamic Hardness Tester FANSE Micrometer 240 60 150
4) PART NAME: - SUPPORT PLATE Raw Material Size: -55X 65X 15
Operation
Machine
Tool Used
Feed
Speed Depth Inspection of cut Instruments
TIME (MIN)
Blank Milling
0.05 mm
600 rpm
3mm
210
Fitter Marking & Drilling
60
Surface Grinding
451P PRAGA Surface Grinding Machine
Grindin g Wheel
Micrometer
120
Jig Boring dia.6H7(4 holes)
Jig Boring Machine (CBH 100)
Jig Boring Tool
0.05 mm
800 rpm
2mm
90
Material: - M.S.
5) PART NAME: - RESTING PAD Raw Material Size: - 45X 65X 15 Material: -O.H.N.S.: - SUPPORT PIN Raw Material Size: - 45X 65X 15
Material: - O.H.N.S. Sr. No. 1 Blank Milling BFW HF2 091 Milling Machine 2 Fitter Marking & Drilling 3 Heat Treatment Dielectric Hardening 4 Surface Grinding 452P PRAGA Surface Grinding Machine 5 Dia. 20 Wire Cut Wire Cut EDM Machine 6) PART NAME: - LOCATING PIN Raw Material Size: - 24 X 42L Material: O.H.N.S Vernier calliper and Micrometer 240 Grinding Wheel Vernier calliper and steel rule Dynamic Hardness Tester FANSE Micrometer 90 60 90 Operation Machine Tool Used Tmax & End Mill cutter 0.05 mm 900 rpm Feed Speed Depth of cut 2mm Inspection Instruments Vernier calliper TIME (MIN) 90
Sr. No. 1
Operation
Machine
Tool Used
Feed
Speed
Depth of cut
Inspection Instruments Vernier calliper and steel rule
TIME (MIN) 90
Turning
LB17 Lathe Machine
Single point cutting tool
0.01 mm
900 rpm
2mm
Heat Treatment Hardening
Dynamic Hardness Tester FANSE
60
Milling
Tmax & End Mill cutter Cylindrical Grinder
0.05 mm
800 rpm
2mm
Vernier calliper and steel rule Micrometer
120
Cylindrical Grinding
Cylindrical Grinding Machine GCU 250 PARISHU DH
150
7) PART NAME: - GUIDE ROD Raw Material Size: - 10X 80L Material: - EN353
Sr. No. 1
Operation
Machine
Tool Used
Feed
Speed
Depth of cut
TIME (MIN) 60
Turning
LB 17 Lathe
0.01 mm
900 rpm
1mm
Dynamic Hardness Tester FANSE Cylindrical Grinding Machine GCU 250 PARISHU DH Cylindrical Grinder Micrometer
60
90
8) PART NAME: - GUIDE PLATE Raw Material Size: - 50 X 30 X 20 Material: - M.S.
Sr. No. 1
Operation
Machine
Tool Used
Feed
Speed
Depth of cut
TIME (MIN) 120
Milling
0.05 mm
800 rpm
2mm
Vernier calliper and steel rule 451P PRAGA Surface Grinding Machine Grinding Wheel Micrometer
60
Surface Grinding
90
Jig Boring
Jig Boring Tool
0.05 mm
1000 rpm
2mm
180
9) PART NAME: - GUIDE PIN Raw Material Size:- 22X 105L
Material: - M.S. Sr. No. 1 Turning LB 17 Lathe Machine Operation Machine Tool Used Single point cutting tool 2 Milling FN3V 1482 BFW Milling Machine 3 Driling Radial Drilling Machine RM62 6410 4 Cylindrical Grinding Cylindrical Grinding Machine GCU 250 PARISHU DH Cylindri cal Grinder Micrometer 210 Drill of Dia.4 0.05 mm 625 rpm 2mm Vernier calliper 60 End Mill cutter 0.05 mm 600 rpm 3mm Vernier calliper and steel rule 120 0.05 mm 900 rpm Feed Speed Depth of cut 2mm Inspection Instruments Vernier calliper and steel rule TIME (MIN) 150
10) PART NAME: - CYLINDER MOUNTING BLOCK Raw Material Size: - 65X 30L Material: - EN8
Sr. No. 1
Operation
Machine
Tool Used
Feed
Speed
Depth of cut
TIME (MIN) 120
Turning
LB 17 Lathe Machine
0.05 mm
1000 rpm
2mm
Heat Treatment Toughning
60
Surface Grinding
Grinding Wheel
Micrometer
60
11)PART NAME: - SUPPORT PIN Raw Material Size: - 10X 30L Material: - EN8
Sr. No. 1
Operation
Machine
Tool Used
Feed
Speed
Depth of cut
TIME (MIN) 60
Turning
LB 17 Lathe Machine
0.05 mm
1000 rpm
2mm
Milling
BFW HF2 091 Milling Machine
End Mill cutter
0.05 mm
800 rpm
2mm
90
Surface Grinding
Grindin g Wheel
Micrometer
90
12) PART NAME: - SUPPORT BLOCK
Raw Material Size: - 80X 85L Material: - M.S.
Sr. No. 1
Operation
Machine Tool Used
Feed
TIME (MIN) 180
Turning
LB 17 Lathe
Single point
0.05 mm
1000 rpm
2mm
Machine cutting tool 2 Fitter Marking & Drilling 3 Milling BFW VF2 Milling Machine 4 Heat Treatment Case Hardening 5 Surface Grinding 451P PRAGA Surface Grindin g Machine Grindin g Wheel End Mill cutter 0.05 mm 800 rpm 2mm
Vernier calliper and steel rule Vernier calliper and steel rule
240
120
Dynamic Hardness Tester FANSE Micrometer
60
120
13) PART NAME: - FIXED BLOCK
Raw Material Size: - 98 X 65 X 45 Material:- EN353 Sr. No. 1 Blank and Step Milling BFW VF2 Milling Machine 2 Fitter work (Marking, Drilling, Tapping) 3 Heat Treatment Case Hardening 4 Surface Grinding PRAGA 451 Surface Grinding Machine 5 Slots Dekel Milling Machine FP4M. 1549 End Mill Cutter 0.05 mm 650 rpm 2mm Vernier calliper and steel rule 180 Grinding Wheel Dynamic Hardness Tester FANSE Micrometer 240 60 No.6 tap, Drill of 7&11 Vernier calliper and steel rule 330 Operation Machine Tool Used Tmax & End Mill cutter 0.05 mm 650 rpm Feed Speed Depth of cut 3mm Inspection Instruments Vernier calliper and steel rule TIME (MIN) 330
7H7, 6H7 Dowel
Jig Boring
Jig Boring Tool
0.05 mm
650 rpm
3mm
210
Machine (Double
Column) 7 Dia. 18 Wire Cut CNC Spark Errosion EDM Machine Copper Electrode Vernier calliper 120
14) PART NAME: - ORIENTATION BLOCK Raw Material Size: - 78X 37X 19 Material: - EN353
Sr. No. 1
Operation
Machine Tool Used
Feed
Speed Depth Inspection of cut Instruments Vernier calliper
TIME (MIN) 60
Turning
LB17 Lathe
Turning &
0.1 mm
1000 rpm
2mm
Machine Facing Tool 2 Step Milling BFW Tmax & 0.05 mm 600 rpm 3mm Vernier calliper 180
HF2 091 End Milling Fitter Marking & Drilling Mill
Machine Cutter 3 Vernier calliper and steel rule 150
Dynamic Hardness Tester FANSE CNC Micrometer
60
Surface
240
Grinding
Arc Milling Machine
15) PART NAME: - SUPPORT PLATE Raw Material Size: - 65X 15X 50 Material: - M.S.
Sr. No. 1
Operation
Machine
Tool Used
Feed
Speed
Depth of cut
TIME (MIN) 210
Blank Milling
0.05 mm
600 rpm
3mm
90
Surface Grinding
120
Jig Boring dia.6H7(4 holes)
Jig Boring Machine (CBH 100)
Jig Boring Tool
0.05 mm
800 rpm
2mm
90
16) PART NAME: - GUIDE ROD
Raw Material Size: - 15 X 85 Material: - EN353
Sr. No. 1
Operation
Machine
Tool Used
Feed
Speed
Depth of cut
Inspection Instruments Vernier calliper and steel rule Dynamic Hardness Tester FANSE
TIME (MIN) 60
Turning
LB 17 Lathe
0.01 mm
900 rpm
1mm
30
Cylindrical Grinder
Micrometer
90
17) PART NAME: - GUIDE PLATE Raw Material Size: - 65 X 50X50 Material: - M.S.
Sr. No.
Operation
Machine
Tool Used
Feed
Speed
Dept h of cut
TIME (MIN)
Milling
0.05 mm
800 rpm
2mm Vernier calliper and steel rule
120
60
Surface Grinding
90
Jig Boring
Jig Boring Tool
0.05 mm
1000 rpm
2mm Vernier calliper and Micrometer
180
18) PART NAME: -PIN Raw Material Size: - 20X 65 Material: - EN8
Sr. No. 1
Operation
Machine
Tool Used
Feed
Speed
Depth of cut
TIME (MIN) 150
Turning
LB 17 Lathe Machine
Single point cutting
0.05 mm
1000 rpm
2mm
tool 2 Heat Treatment Toughening Dynamic Hardness Tester FANSE 3 Cylindrical Grinding Cylindrical Grinding Machine GCU 250 PARISHU DH Cylindri cal Grinder Micrometer 210 60
19) PART NAME: - CLAMPING PAD Raw Material Size: - 65X 40X 22 Material: - O.H.N.S.
Sr. No. 1
Operation
Machine
Tool Used
Feed
Speed
Depth of cut
TIME (MIN) 180
Blank and Step Milling
BFW HF2 091 Milling Machine
0.05 mm
700 rpm
2mm
Fitter Marking &
Vernier calliper and
60
Milling 3 Surface Grinding 451P PRAGA Surface Grinding Machine 4 Drilling Jig Boring Machine (Double Column) 0.05 mm 800 rpm 3mm Grinding Wheel
steel rule Micrometer 210
Vernier calliper
60
20) PART NAME: - SWING ARM Raw Material Size: - 205X 38X 28 Material: - EN8
Sr. No. 1
Operation
Machine
Tool Used
Feed
Speed
Depth of cut
TIME (MIN) 300
Milling
BFW FN3V 1482 Milling Machine
End Mill cutter
0.05 mm
600 rpm
3mm
Drilling
Drilling Machine
0.12 mm
900 rpm
2mm
Vernier calliper
210
BVR3 3 Heat Treatment Toughning Dynamic Hardness Tester FANSE 4 Surface Grinding 451P PRAGA Surface Grinding Machine 5 Wire Cut CNC Spark Errosion Machine Vernier calliper and Micrometer 300 Grinding Wheel Micrometer 180 60
21) PART NAME: -CYLINDRICAL MOUNTING PLAE Raw Material Size: - 75X 65X 35 Material: - M.S.
Sr. No. 1
Operation
Machine
Tool Used
Feed
TIME (MIN) 240
Milling
End Mill cutter
0.05 mm
800 rpm
2mm
Fitter Marking & Chamfering
Vernier calliper and steel rule Drilling Machine 0.12 mm 900 rpm 2mm Vernier calliper
60
Drilling
120
BVR3 4 Surface Grinding 451P PRAGA Surface Grinding Machine 5 Jig Boring HOR Jig Boring Machine CBH 100 Jig Boring Tool 0.05 mm 800 rpm 3mm Vernier calliper and Micrometer 90 Grinding Wheel Micrometer 180
22) PART NAME: - CYLINDRICAL STOPPER Raw Material Size:- 110 X 55X 20 Material: - M.S.
Sr. No. 1
Operation
Machine Tool Used
Feed
TIME (MIN) 300
Milling
BFW
End
0.05 mm
800 rpm
2mm
HF2 091 Mill Milling Machine 2 Fitter Marking Cutter
30
Welding
Welding Machine
60
Slot Milling
Deckel Milling
End Mill
0.05 mm
650 rpm
2mm
150
Machine Cutter FP4M 1589
steel rule
23) PART NAME: - RESTING PAD Raw Material Size: - 65X 50X 25 Material: - EN8
Sr. No. 1
Operation
Machine Tool Used
Feed
Speed
Depth Inspection of cut Instruments Vernier calliper and steel rule
TIME (MIN) 240
Blank Milling
BFW FNV 1482 Milling Machine
0.1. mm
800 rpm
2 mm
Fitter Marking
40
Slot Milling Deckel Milling Machine
End Mill Cutter
0.05 mm
650 rpm
2mm
240
Surface Grinding
Grinding Wheel
Micrometer
240
EDM Slot
CNC Spark Errosion Machine FP4M 1589
Copper Electrode
300
Drilling
Drilling Machine BVR3
Drill
0.12 mm
900 rpm
2mm
Vernier calliper
60
60
24) PART NAME: - RESTING PAD Raw Material Size: - 65 X 50X 25 Material: - EN8
Sr. No. 1
Operation
Machine
Tool Used
Feed
Speed
Depth of cut
TIME (MIN) 240
Blank Milling
BFW FNV 1482
0.1. mm
800 rpm
2 mm
Milling Machine 2 Fitter Marking Vernier calliper and steel rule 3 Slot Milling Deckel Milling Machine FP4M 1589 4 Drilling Drilling Machine BVR3 5 Heat Treatment Toughning Dynamic Hardness Tester FANSE 6 Surface Grinding 451P PRAGA Surface Grinding Machine 7 EDM Slot CNC Spark Errosion Machine Copper Electrode 300 Grinding Wheel Micrometer 240 30 Drill 0.12 mm 900 rpm 2mm Vernier calliper 60 End Mill Cutter 0.05 mm 650 rpm 2mm Vernier calliper and steel rule 240 40
Sr.N o. 1
Operation
Machine
Tool Used
Feed
TIME (MIN) 240
Blank Milling
0.1. mm
800 rpm
2 mm
Fitter Marking
60
Slot Milling Deckel Milling Machine FP4M 1589
End Mill Cutter
0.05 mm
650 rpm
2mm
240
Drilling
Drill
0.12 mm
900 rpm
2mm
Vernier calliper
45
60
Surface Grinding
Grinding Wheel
Micrometer
240
EDM Slot
CNC Spark Errosion Machine
Copper Electrode
Vernier calliper
300
26) PART NAME: - RESTING PAD Raw Material Size: - 65X 50X 25 Material: - EN8
Sr.N o. 1
Operation
Machine
Tool Used
Feed
TIME (MIN) 240
Blank Milling
0.1. mm
800 rpm
2 mm
Fitter Marking
60
End Mill Cutter
0.05 mm
650 rpm
2mm
240
Drilling
Drill
0.12 mm
900 rpm
2mm
Vernier calliper
45
60
Surface Grinding
Grinding Wheel
Micrometer
240
EDM Slot
Copper Electrode
Vernier calliper
300
Sr.N o. 1
Operation
Machine
Tool Used
Feed
TIME (MIN) 240
Blank Milling
BFW FNV 1482 Milling Machine
0.1. mm
800 rpm
2 mm
Fitter Marking
60
End Mill Cutter
0.05 mm
650 rpm
2mm
240
Drilling
Drill
0.12 mm
900 rpm
2mm
Vernier calliper
45
30
Surface Grinding
Grinding Wheel
Micrometer
240
EDM Slot
Copper Electrode
Vernier calliper
300
Sr.N o. 1
Operation
Machine
Tool Used
Feed
Speed
Depth Inspection of cut Instruments Vernier calliper and steel rule
TIME (MIN) 240
Blank Milling
0.1. mm
800 rpm
2 mm
Fitter Marking
60
steel rule 3 Slot Milling Deckel Milling Machine FP4M 1589 4 Drilling Drilling Machine BVR3 5 Heat Treatment Toughning Dynamic Hardness Tester FANSE 6 Surface Grinding 451P PRAGA Surface Grinding Machine EDM Slot CNC Spark Errosion Machine Copper Electro de Vernier caliper and Steel rule 300 Grindin g Wheel Micrometer 240 60 Drill 0.12 mm 900 rpm 2mm Vernier calliper 45 End Mill Cutter 0.05 mm 650 rpm 2mm Vernier calliper and steel rule 240
29) PART NAME: - SPACER PLATE Raw Material Size: - 65 X 25X10 Material: -M.S.
Sr. No. 1
Operation
Machine
Tool Used
Feed
TIME (MIN) 180
Blank Milling
0.05 mm
900 rpm
2mm
Fitter Marking
60
Drilling
BVR3 Drilling Machine
Drill Dia. 7mm
0.12 mm
900 rpm
2mm
Vernier calliper
30
30) PART NAME: - PROBING BUSH Raw Material Size: - 25X 20 Material: -O.H.N.S.
Sr. No.
Operation
Machine
Tool Used
Feed Speed
Depth of cut
TIME (MIN)
Turning
LB 17 Lathe Machine
0.1 mm
1000 rpm
2mm
90
Dynamic Hardness Tester FANSE Internal Grinding Machine TGF 248800248 6 Internal Grinding Tool Micrometer
60
Internal Grinding
60
O.D. Grinding
Cylindrical Grinder
Micrometer
60
ASSEMBLY OF FIXTURE:-
Support plate & Spacer plate are fixed on casting base. Then probing bush is attached to casting base. Fixed block is mounted on casting base. Then guide plate is mounted on fixed block. Now guide rods are located. Then resting pad is arranged on Guide plate. Then Orientation block is mounted on fixed block. Then cylinder stopper is attached. KOSMEK hydraulic cylinders are fixed at their appropriate position. Swing arm is placed at the end of KOSMEK cylinder. Clamping pads are located on swing arm. Then cylinder mounting block is attached to casting base. Then single acting cylinder with 10mm stroke is fixed. Now support block is mounted on casting base with respect to cylinder mounting block. Then guide pin is mounted on support block. Again 7 times above procedure is repeated as there are 8 subassemblies which are similar. At the end, accumulator is mounted on casting base & hydraulic connection is do
WEIGHT CALCULATIONS:-
1) CASTING BASE Specific weight of C.I.=7.85gm/cm cube Raw Material Size: 500X 340X 195 Volume=33150000mm^3=33150.000cm^3 Weight =33150.000*7.85/1000=110 kg Unit cost=Rs.55/kg Cost=110*55=Rs.6050
2) FIXED BLOCK Specific weight of M.S.=7.85gm/cm cube Raw Material Size: 50X 60X 115 Volume=345000mm^3=345.000 cm^3 Weigh =345*7.85/1000=11kg Unit cost=Rs.45/kg Total cost=4*495= Rs.1980
3) ORIENTATION BLOCK Specific weight of EN 353=7.85gm/cm cube Raw Material Size: 70 X 35X20 Volume=49000mm^3=49.00cm^3 Weight =49.00*7.85/1000=9kg Unit cost=Rs.100/kg Cost=9*100=Rs.900 Total cost=24*900= Rs.21600
4) SPPORT PLATE Raw Material Size: 55 X 65X15 Volume=55 X 65X15=53625 mm^3=53.625cm^3 Weight =53.625*7.85/1000=1.6kg Unit cost=Rs.45/kg Cost=1.6*45=Rs.72 Total cost=4*72= Rs.288
5) RESTING PAD Raw Material Size: 45X65X15 Volume=43875mm^3=43.875cm^3 Weight =43.875*7.85/1000=2.76kg
Unit cost=Rs.100/kg Cost=2.76*100=Rs.276 Total cost=8*276= Rs.2208
6) LOCATING PIN Raw Material Size: D24X42 Volume=3.14*12^2*42=19000.35mm^3=19.000m^3 Weight =19.000*7.85/1000=3.5kg Unit cost=Rs.70/kg Cost=3.5*70=Rs.245 Total cost=2*245= Rs.490 1) GUIDE ROD Raw Material Size Volume=3.14*5^2*80=6283.185mm^3=6.283cm^3 weight=6.283*7.85/1000=0.4 kg Total cost=8*24.4= Rs.195.2Unit cost=Rs.61/kg Cost=0.4*61=Rs.24.4
8)GUIDE PLATE Raw Material Size: 50X30X20 Volume=50X30X20=30000mm^3=30.000cm^3 Weight =30.000*7.85/1000=1kg Unit cost=Rs.45/kg Cost=1*45=Rs.45 Total cost=4*45= Rs.180
9) GUIDE PIN Raw Material Size: D22X105 Volume=3.14*11^2*105=39913.93mm^3 Weight =39913.93*7.85/1000=2.5kg Unit cost=Rs.45/kg Cost=2.5*45=Rs.112.5 Total cost=8*112.5= Rs.900
10) CYLINDER MOUNTING BLOCK Raw Material Size: D65X30 Volume=99549.21mm^3=99.549cm^3 Weight =99.549*7.85/1000=6.20kg Unit cost= Rs. 55/kg Cost=6.2*55=Rs.341 Total cost=8*341= Rs.2728
11) SUPPORT PIN Raw Material Size: D10X30 Volume=2356.19mm^3=2.356cm^3 Weight =2.356*7.85/1000=0.1kg Unit cost=Rs. 55/kg Cost=0.1*55=Rs.5.5 Total cost=8*5.5= Rs.44 12) SUPPORT BLOCK Raw Material Size: D80X85 Volume=427256.60mm^3=427.256cm^3 Weight =427.256*7.85/1000=27kg Unit cost=Rs.45/kg Cost=27*45=Rs.1215 Total cost=8*1215= Rs.9720
13) FIXED BLOCK Raw Material Size: 98X65X45 Volume=98X65X45=286650mm^3=286.650cm^3 Weight =286.650*7.85/1000=10kg Unit cost=Rs.45/kg Cost=10*45=Rs.450 Total cost=4*450= Rs.1800
14) ORIENTATION BLOCK Raw Material Size: 78X37X20 Volume=57720mm^3=57.720cm^3
Weight =57.720*7.85/1000=10.6kg Unit cost=Rs.100/kg Cost=10. 6*100=Rs.1060 Total cost=24*1060= Rs.25440
15) SUPPORT PLATE Raw Material Size: 65X15X50 Volume=48750mm^3= 48.75cm^3 Weight =48.75*7.85/1000=1.45kg Unit cost=Rs.45/kg Cost=1.45*45=Rs65.25 Total cost=4*65.25= Rs.261 16) GUIDE ROD Raw Material Size: D15X85 Volume=15020.74mm^3= 15.02cm^3 Weight =15.02*7.85/1000=0.96kg Unit cost=Rs.61/kg Cost=0.96*61=Rs.58.56 Total cost=8*58.56= Rs.468.5
17) GUIDE PLATE Raw Material Size: 65X50X50 Volume=162500mm^3= 162.5cm^3 Weight =162.5*7.85/1000=5.4kg Unit cost=Rs.45/kg Cost=5.4*45=Rs.243 Total cost=4*243= Rs.972
18) PIN Raw Material Size: D20X65 Volume=20420.35mm^3= 20.42cm^3 Weight =20.42*7.85/1000=1.28kg Unit cost=Rs.45/kg Cost=1.28*45=Rs57.6
Total cost=8*57.6= Rs.460
19) CLAMP PAD Raw Material Size: 65X40X22 Volume=57200mm^3= 57.2cm^3 Weight =57.2*7.85/1000=3.5kg Unit cost=Rs.100/kg Cost=3.5*100=Rs.350 Total cost=8*350= Rs.2800 20) SWING ARM Raw Material Size: 205X28X38 Volume=218120mm^3= 218.12cm^3 Weight =218.12*7.85/1000=7kg Unit cost=Rs.55/kg Cost=7*55=Rs.385 Total cost=4*385= Rs.1540
21) CYLINDER MOUNTING PLATE Raw Material Size: 75X65X35 Volume=170625mm^3= 170.625cm^3 Weight =170.625*7.85/1000=5.44kg Unit cost=Rs.45/kg Cost=5.44*45=Rs.244.8 Total cost=4*244.8= Rs.979.2
22) CYLINDER STOPPER Raw Material Size: 110X55X20 Volume=121000mm^3= 121.00cm^3 Weight =121.00*7.85/1000=7.6kg Unit cost=Rs.45/kg Cost=7.6*45=Rs.342 Total cost=8*342= Rs.2736
23) RESTING PAD
Raw Material Size: 65X50X25 Volume=81250mm^3= 81.25cm^3 Weight =81.25*7.85/1000=2.5kg Unit cost=Rs.55kg Cost=2.5*55=Rs.137.5 Total cost=4*137.5= Rs.550 26) RESTING PAD Raw Material Size: 65X50X25 Volume=81250mm^3= 81.25cm^3 Weight =81.25*7.85/1000=2.5kg Unit cost=Rs.55kg Cost=2.5*55=Rs.137.5 Total cost=4*137.5= Rs.550
27) RESTING PAD Raw Material Size: 65X50X25 Volume=81250mm^3= 81.25cm^3 Weight =81.25*7.85/1000=2.5kg Unit cost=Rs.55kg Cost=2.5*55=Rs.137.5 Total cost=4*137.5= Rs.550
28) RESTING PAD Raw Material Size: 65X45X25 Volume=73125mm^3= 73.125cm^3 Weight =73.125*7.85/1000=2.25kg Unit cost=Rs.55kg Cost=2.25*55=Rs.123.75 Total cost=4*123.75= Rs.495
29) SPACER PLATE Raw Material Size: 65X25X10 Volume=16250mm^3= 16.25cm^3 Weight =16.25*7.85/1000=0.5kg
Unit cost=Rs.45/kg Total cost=4*22.5= Rs.90 Cost=0.5*45=Rs.22.5 30) PROBING BUSH Raw Material Size: 25X 20 Volume=9817.48mm^3= 9.817cm^3 Weight=9.817*7.85/1000=0.6kg Unit cost=Rs.70/kg Cost=0. 6*70=Rs.42 Total cost=4*42= Rs.168
BOUGHT OUT COMPONENTS

Sr. No. Material Description Quantity Cost/Unit In Rs. Total Cost In Rs.
LIST OF MATERIAL FOR HYDRAULIC ARRANGEMENT

Flat--End Pieces Plates-Flat--End Pieces Plates-Flat--End Pieces Plates-Tube Seamless 6X1mm Ferrule L6 PMS Coupling CP6-LR 1/8 CX6-L/R bsp TTMSCO Item Quick Coupler suitable for 200 bar 0.23 0.56 0.28 1 6 2 1 2 34 34 34 32.5 7.5 19 22 840 7.82 19.245 9.52 32.5 45 38 22 1680
Plug MS inch
10
Ball Valve inch bsp Heavy Duty Accumulator VEKTEK make model 49-0116-02 Liner Bush EN353 ID 20mmX25mm L Processed HYD _CYL KOSMEK LV 0550-C-P Clockwise HYD _CYL KOSMEK LV 0550-C-P Counter Clockwise Wiper Rod ID 6,OD 12 Thick 3.5mm Wiper Rod ID 12,OD 21 Thick 5mm HYD _CYL 10mm Stroke Single Acting No DP0 Valve Sequence Quicloc Make No. V11101
1 1
1260 10450
1260 10450
2 2 2 10 10 8 1
50.01 30352.005 30352.005 67.5 76.5 5485.96 6334.52
100.02 60704.01 60704.01 675 765 43887.68 6334.52
:
SR NO 1 2 3 4 5 6 7 8 9 10 DETAILS QNTY MATERIALS PURCHASE PRICE IN RS. C.I. M.S. EN353 M.S. OHNS OHNS EN353 M.S. M.S. EN8 6050 1980 21600 288 2208 490 195.2 180 900 2728
CASTING BASE FIXED BLOCK ORIENTATION BLOCK SPPORT PLATE RESTING PAD LOCATING PIN GUIDE ROD GUIDE PLATE GUIDE PIN CYLINDER MOUNTING BLOCK SUPPORT PIN SUPPORT BLOCK FIXED BLOCK ORIENTATION BLOCK SUPPORT PLATE GUIDE ROD GUIDE PLATE PIN CLAMPING PAD SWING ARM CYLINDER MOUNTING PLATE
1 4 24 4 8 20 8 8 4 8
11 12 13 14 15 16 17 18 19 20 21
8 8 4 24 4 8 4 8 8 4 4
EN8 M.S. M.S. EN353 M.S. EN353 M.S. EN8 OHNS EN8 4 M.S.
44 9720 1800 25440 261 468.5 972 460.8 2800 1540 979.2
CONCLUSION:
We have developed fixture for vertical machining centre (VMC). We have succeeded in designing of fixtures as per specifications.. We have done this with optimum cost of efficiency; the accuracy of work piece produce by using the fixture is to the satisfaction.This has resulted in case of operation and handling without affecting the accuracy of work piece. This project work has given us experience about overall design and manufacturing activities that take place in the Engineering Industry We have interacted with lot of people during our project work. Involving in this project was an exiting and learning experience for use. This project work has broadened our horizons. This experience will definitely help us in our future for developing ourselves as good Engineers.
BIBLIOGRAPHY
1. Production Engineering- P. C. Sharma. 2. Production Technology- R. K. Jain. 3. An introduction to jig and Tool Design- M. H. A. Kempster ELBS. 4. Machine Design- R. S. Khurmi. 5. Production Technology- H. M. T. Handbook 6. Auto Cad- 2009 7. www.kosmek.com 8. www.enercap.mht.com 9. www.vektek.com

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HYDRAULIC CLAMPING ARRANGEMENT FOR CONNECTING ROD MILLING FIXTURE

COMPONENTS USED FOR HYDRAULIC CLAMPING

DESIGN PRINCIPLE FOR FIXTURE

HOR Boring Machine CBH 100

Vernier calliper and steel rule

HOR Boring Machine CBH 100

Various sizes of drills Dia 67.5,13.5, 6 Reamer dia. 14

HOR Boring Machine CBH 100

Size 50 boring tool

Vernier caliper, Micrometer

HOR Boring Machine CBH 100

ELB Surface Grinding Machine

Fitter work including dia. 8 extra long drills, tapping

ELB Surface Grinding Machine

Vernier calliper and steel rule

Slots of 14 Dekel mm Milling Machine,

End Mill cutter dia.12

Vernier calliper and steel rule

TIME (MIN) 350

Blank and Step Milling

BFW VF2 Milling Machine

Tmax & End Mill cutter

Fitter work (Marking, Drilling, Tapping)

No.6 tap, Drill of 7&11

Vernier calliper and steel rule

Heat Treatment Case Hardening

Dekel Milling Machine FP4M. 1549

End Mill Cutter

Vernier calliper and steel rule

7H7, 6H7 Dowel

Jig Boring Machine (Double Column)

Jig Boring Tool

Vernier calliper and Micrometer

Dia. 18 Wire Cut

CNC Spark Errosion EDM Machine

Machine Tool Used

Speed Depth Inspection of cut Instruments Vernier

4) PART NAME: - SUPPORT PLATE Raw Material Size: -55X 65X 15

Speed Depth Inspection of cut Instruments

BFW VF2 Milling Machine

Tmax & End Mill cutter

Vernier calliper and steel rule

Fitter Marking & Drilling

Vernier calliper and steel rule

451P PRAGA Surface Grinding Machine

Jig Boring dia.6H7(4 holes)

Jig Boring Machine (CBH 100)

Jig Boring Tool

Vernier calliper and Micrometer

Inspection Instruments Vernier calliper and steel rule

LB17 Lathe Machine

Single point cutting tool

Heat Treatment Hardening

Dynamic Hardness Tester FANSE

BFW VF2 Milling Machine

Tmax & End Mill cutter Cylindrical Grinder

Vernier calliper and steel rule Micrometer

Cylindrical Grinding Machine GCU 250 PARISHU DH

Inspection Instruments Vernier calliper and steel rule

Single point cutting tool

Heat Treatment Case Hardening

8) PART NAME: - GUIDE PLATE Raw Material Size: - 50 X 30 X 20 Material: - M.S.